Pigmented radiation cured wear layer

ABSTRACT

A method and composition for providing a colored high performance wear surface for floor coverings is disclosed. Specifically, the floor covering includes a substrate and a high performance layer comprising a radiation cured pigmented composition. The exposed surface of the floor covering has a stain resistance of less than about 150 Delta E units. A pigmented high performance wear layer can be added in register with a printed design on the substrate or in register with an embossed texture of the substrate. Additionally, a high performance topcoat wear layer may be added. The pigmented high performance layer may include a nacreous pigment.

FIELD OF THE INVENTION

The present invention relates to a floor covering having a radiationcurable high performance pigmented topcoat layer and a floor coveringhaving a radiation curable high performance topcoat adjacent a radiationcurable high performance pigmented wear layer.

BACKGROUND

Resilient floor coverings can be formed into sheets or individual tiles.Typically, in the manufacture of a resilient floor covering, a wearlayer is combined with a substrate and resin to form the resilient sheetor tile. The substrate usually comprises a felted or matted fibroussheet of overlapping, intertwined filaments or fibers. To the substrateis typically applied a substantially uniform layer of a liquid orsemi-liquid resinous composition containing a synthetic polymericmaterial, usually an ungelled polyvinyl chloride plastisol and a blowingor foaming agent. The liquid or semi-liquid plastisol vinyl resincomposition is subsequently firmed or gelled at an elevated temperature.This gelled plastisol may be printed with a decorative pattern or designhaving a blowing or foaming inhibitor for chemically embossing thesubstrate.

A wear layer is often applied to the surface of the polyvinyl chlorideplastisol disposed on the substrate. Generally, the wear layer consistsof a transparent layer that imparts resistance to puncture. Thesetypically consist of a layer of transparent polyvinyl chloride, buturethane and urethane acrylates have been utilized. Additionally, theremay also be applied another transparent topcoat layer that improves thestain and scratch resistance of the composite's surface. Examples ofsuch wear layer composites can be found in U.S. Pat. Nos. 4,333,987,4,180,615, 4,393,187 and 4,507,188.

A wear layer is any layer which improves the performance of the floorcovering, such as an improved gouge, tear and rip resistance, improvedstain resistance, or improved scratch resistance. A topcoat is a wearlayer that has at least a portion that forms the exposed surface of thefloor covering. A high performance wear layer or topcoat is a generallythin (less than about 3 mils) wear layer or topcoat formed from aradiation, e.g. ultraviolet (UV) or electron beam (EB), curedcomposition.

High performance wear layers or topcoats are cured by radiation toenhance their durability and finish. Radiation curable coatings aretypically cured by exposure to ionizing irradiation or ultravioletlight. Such coatings are known in the art; for example, urethanecoatings cured with ultraviolet light to provide protective wear layersfor wall or floor tiles are described in U.S. Pat. No. 4,180,615.Additionally, in U.S. Pat. No. 3,918,393, there is described a methodfor obtaining a non-glossy coating on various substrates by curingradiation sensitive material with ionizing irradiation or ultravioletlight in two stages. In this process, the coating is partially cured inan oxygen-containing atmosphere and later completed in an inertatmosphere. In each of the above examples, the wear layer isunpigmented.

Unfortunately, radiation curable wear layers and topcoats are subject tosubstantial difficulties when coloring is added. Coloring is added bythe addition of various pigments to the wear layer. The incorporation ofpigment, especially enough pigment to make the coating opaque, producesa coating which is hard to cure and therefore reduces durability. Thereare no known floor coverings that include a pigmented high performancetopcoat or a pigmented high performance wear layer which is covered by ahigh performance topcoat. Thus, there is a need for a pigmented highperformance topcoat or a combination of a pigmented high performancewear layer/high performance topcoat on the up areas of an embossed floorcovering having a sufficient durability to function on a decorativefloor covering.

SUMMARY

The present invention comprises both a method and composition forproviding a pigmented high performance topcoat or the combination of apigmented or unpigmented high performance topcoat and a pigmented highperformance wear layer which is adjacent to the high performance topcoatfor decorative floor coverings. Specifically, one embodiment of thedecorative floor covering includes a substrate and a high performancetopcoat comprised of a radiation cured pigmented topcoat wear layerhaving a stain resistance of about less than 150 Delta E units disposedon the substrate. The high performance topcoat may be unpigmented if itis applied over a second pigmented high performance wear layer. Onlysome portions of the topcoat and/or wear layer need to be pigmented. Inone embodiment, the wear layer on the up areas of an embossed flooringsurface is pigmented. In one embodiment the stain resistance is lessthan about 150 Delta E units.

In one embodiment, the pigment concentration is between about 0.25 toabout 20 weight percent. In another embodiment, the pigmentconcentration is between about 1 and 10 weight percent. The curedpigmented high performance topcoat and/or wear layer can be added inregister with a printed design or in register with an embossed textureof the substrate. Nacreous pigments can be used in either or bothtopcoat wear layers to get enhanced visual effects.

A further embodiment includes a decorative floor covering componentcomprising a film and a radiation cured pigmented high performancetopcoat having a stain resistance of about less than 150 Delta E unitsdisposed on the film. The radiation cured pigmented topcoat can also bedisposed in register with a printed design on the film. The film mayalso comprise a radiation cured pigmented high performance wear layerand a radiation cured unpigmented high performance topcoat.

The method of manufacturing a decorative floor covering having apigmented high performance topcoat includes manufacturing the decorativefloor covering comprising applying a pigmented topcoat to a substrateand curing by radiation to form a topcoat having a stain resistance ofabout less than 150 Delta E units. The pigmented topcoat can, in onecase, be cured by either radiation from ultraviolet or electron beamradiation. The substrate may also be mechanically or chemically embossedbefore or after applying the pigmented high performance topcoat. Thesubstrate may also comprise a pigmented or unpigmented wear layer orpigmented or unpigmented high performance wear layer component, as wellas a foamed or unfoamed resin layer.

Another embodiment includes a method for manufacturing a floor coveringcomponent. The floor covering component can be manufactured by applyinga pigmented high performance topcoat to a film and curing the pigmentedtopcoat by subjecting the layer to radiation. The component can then beapplied to a substrate. The film can also comprise a high performancewear layer onto which the pigmented high performance topcoat is appliedand cured.

In another embodiment, a method for manufacturing a floor coveringhaving an unpigmented high performance topcoat and a pigmented highperformance wear layer adjacent the topcoat includes manufacturing thedecorative floor covering by applying a pigmented high performance wearlayer. In one embodiment the pigmented high performance wear layer isapplied to the up areas of an embossed substrate. In either case, thepigmented high performance wear layer is at least partially cured andthen an unpigmented high performance topcoat is applied and subjected toradiation to form a topcoat having a stain resistance of about less than150 Delta E units. The pigmented wear layer can, in one case, be eitherradiation cured by ultraviolet or electron beam radiation. The pigmentedhigh performance wear layer cures sufficiently to improve the wearperformance of the unpigmented topcoat.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a decorative floor covering having apigmented radiation cured topcoat and a substrate wherein the topcoat isin register with a printed pattern on the substrate;

FIG. 2 is a cross-sectional view of a decorative floor covering having apigmented high performance wear layer, a unpigmented radiation curedtopcoat and a substrate wherein the high performance wear layer is inregister with a printed pattern on the substrate and the topcoat isapplied to substantially the entire substrate;

FIG. 3 is a cross-sectional view of a decorative floor covering having apigmented radiation cured topcoat and a substrate wherein the topcoat isin register with an embossed pattern;

FIG. 4 is a cross-sectional view of a decorative floor coveringcomprising a pigmented radiation cured high performance wear layer,pigmented or unpigmented radiation cured topcoat and a substrate whereinthe high performance wear layer is applied to the substrate in registerwith a printed and/or embossed design, and the topcoat is applied tosubstantially the entire substrate;

FIG. 5 is a cross-sectional view of FIG. 4 wherein the up areas havebeen mechanically embossed with a fine embossing pattern;

FIG. 6 is a cross-sectional view of the back printed film and appliedpigmented radiation cured topcoat layer;

FIG. 7 is a cross-sectioned view of a back printed film with appliedpigmented radiation cured high performance wear layer and topcoat;

FIG. 8 is a cross-sectional view of a decorative floor coveringillustrating a covering produced by a “kiss coating” process wherein thetopcoat is applied to the raised portions of the decorative floorcovering;

FIG. 9 is a cross-sectional view of a decorative floor coveringillustrating a covering produced by a “shade wiping” process wherein thetopcoat is applied to the recesses of the decorative floor covering;

FIG. 10 is a cross-sectional view of a decorative floor coveringillustrating a floor covering produced by chemically embossing asubstrate having a wear layer covering the entire surface of the floorand then screen printing a radiation cured high performance wear layerin register, mechanically embossing the composite and applying a highperformance topcoat over substantially the entire surface of thecovering; and

FIG. 11 illustrates a sample arrangement for a modified Tabor Abrader.

DETAILED DESCRIPTION

The present invention comprises both a method and composition forproviding a pigmented radiation cured high performance topcoat fordecorative floor coverings, or the combination of a pigmented orunpigmented high performance topcoat and a adjacent pigmented highperformance wear layer. In one embodiment the pigmented wear layer is onthe up areas of an embossed floor covering surface. Specifically, in oneembodiment, the decorative floor covering includes a substrate and ahigh performance wear surface comprising a radiation cured pigmentedhigh performance topcoat having a stain resistance of about less than150 Delta E units disposed on the substrate.

Referring to FIG. 1, the substrate 2 forms the base of the decorativecovering and can be selected from, but not limited to, sheet, tile,strip, board, parquet, and the like. Such a substrate 2 can comprisemonomers, polymers, plastics, resins, including reinforced resins,rubbers, papers, cloths, metals, wood, composites, veneers andlaminates. The substrate 2 may be decorative and have any desired coloror colors, printed characters, design, patterns, etc., as is the casewith colored, printed, or decorative tiles, sheets, and laminates.

The substrate 2 can also comprise a wear layer or composite wear layerwhich can include a high performance wear layer or topcoat. Examples ofsubstrates 2 which may be employed in the present invention aredescribed in U.S. Pat. Nos. 6,006,486, 4,804,429, 4,574,065, 3,293,108,and 3,293,094 and PCT Patent Application Serial No. WO 99/66151, all ofwhich are incorporated herein in their entirety by reference.

The pigmented high performance topcoat 4 and wear layer 5 (FIGS. 1 and2) can comprise any radiation curable composition including thosecontaining unsaturation such as acrylate, methacrylate, vinyl ethers, ormaleic acid type polyesters, or those of irradiation active moietiessuch as radiation curable epoxy or epoxy acrylate systems. There is nolimitation on the chemistry of the coating composition except that itcan be cured while highly pigmented and has acceptable performancecharacteristics as a high performance flooring wear surface. Such highperformance characteristics include a stain resistance of about lessthan about 150 Delta E units and gloss retention properties of about 80%or higher. Polyurethane acrylate and polyester acrylate compositions areexamples which may be incorporated within the coating.

Examples of test procedures and definitions of such characteristics aredisclosed in U.S. Pat. No. 5,843,576, which is incorporated herein inits entirety by reference. The Gloss Retention Test Procedure isdescribed in this and the following two paragraphs. Flooring samples 4inch by 4 inch were adhered to 4 inch by 4 inch by ¼ inch aluminumplates using two-faced tape and conditioned at least 24 hours at 73.4°F. and 50% humidity. Initial Gloss readings (average of 20 readings)were taken on each sample using a Hunter Lab Gloss Meter and recorded.These samples were placed into a large scale Tabor Abrader consisting ofa flat, round aluminum table with 24, 4 inch by 4 inch by ¼ inch cutoutswith an inside diameter of 37½ inches and an outside diameter of 45½inches (See FIG. 11). A 4 inch wide leather abrading wheel traveledaround the table contacting the surface of the flooring samples. Thewheel was attached to a center arm mechanism that moved the wheel aroundthe table at 7.6 revolutions a minute. The wheel was also independentlydriven so that wheel rotated at 25 rpm independent of the center arm.This imparts a positive “slip” between the flooring samples and theleather surface of the wheel.

The leather abrading wheel consisted of a 20 inch diameter aluminumwheel weighing 40 lbs., and covered with a 4 inch wide, ½ inch thickhigh density elastomeric foamed sheet (Astroturf Backing of about 10lbs./cubic foot density, obtained from Armacell LLC, 7600 Oakwood StreetExtension, PO Box 1038, Mebane, N.C. 27302) adhered to the aluminumwheel with two faced tape.

A 4 inch leather belt, {fraction (14/64)} inches thick; 66⅝ inches netlength (69⅝ inch gross length skived 3 inches from each end for overlap)was obtained from R/W Connection, 936 Links Ave, Landisville, Pa. 17538,and adhered to the face of the elastomeric foamed sheet with two-facedtape providing an essentially continuous leather belt surface.

The center arm was also equipped with a “soil” feeder directly oppositethe wheel that deposits soil on the flooring samples at a rate of 2.8grams over 15 seconds, every 5 minutes and was gently brushed across thesamples. The soil feeder was equipped with a timing device so that the“depositing time” was set for 15 seconds, and the time between soilapplication was set for 4 minutes and 45 seconds. The soil consisted of90% by weight PVC dryblend (100 phr Vygen 85 PVC resin and 33.3 phr ofDOP (dioctyl phthalate) plasticizer. The dry blend was made in aHenschel mixer so that the plasticizer was absorbed and a dry powderobtained.) and 10% by weight #240 aluminum oxide obtained from TaborIndustries.

After 15 minutes into the test, the flooring samples were rotated 90degrees and testing resumed. The flooring samples were rotated 90degrees (in the same direction) after each 15 minute period for a totalof 90 minutes. Samples were removed and cleaned by gently wiping with asoft cloth and gloss readings taken (average of 20 readings). Thepercent gloss retention after 90 minutes was calculated by the followingequation:(Initial Gloss−90 Minute Gloss)/Initial Gloss=% Gloss Retention.

The pigmented topcoat 4 may be applied as a single coating, as shown inFIG. 2, or as a plurality of coatings, as shown in FIG. 1. Additionally,two or more pigmented topcoat layers may be incorporated into thedecorative floor covering. When the high performance topcoat ispigmented, it can be adjacent to a pigmented or unpigmented highperformance wear layer. When the topcoat is unpigmented, it is adjacenta pigmented high performance wear layer.

The pigmented high performance topcoat 4 and wear layer 5 may be curedby exposure to electron beam irradiation. Depending upon thickness ofthe pigmented topcoat, the e-beam conditions can vary from 2 to 20 Mradof exposure for electron energies associated with 100 to 500 KeV e-beamunits. For topcoats that are in the range of 0.2 to 2 mils, electronenergies of about 125 KEV are preferred with exposures of about 2 to 5Mrad.

The pigmented high performance topcoat 4 and wear layer 5 can also becured by exposure to ultraviolet light energies. Standard medium or highpressure mercury vapor type UV lamps with wavelengths of about 1800 to4000 Angstrom units can be employed, as well as UV lamps containingadditives to enhance specific UV regimes, e.g. V or D type bulbs. UVradiation exposure can usually vary from about 1 to 6 joules/sq. cmdepending upon topcoat thickness and pigment loading level.Additionally, photosensitizers can be selected to increase curing rateand sensitivity to specific wavelengths of UV light. The formulationscan be either cured in air or nitrogen depending upon chemistry andphotosensitizers. However, depending upon the chemistry, better stainresistance and gloss retention properties are generally obtained whenfinal cure is done under an inert atmosphere such as nitrogen.

Types of photoinitatiors and photosensitizers that are useful for thisinvention include but are not limited to those summarized below inTables 1 and 2. TABLE 1 List of Photoinitators Trade Name Chemical NameSupplier Darocur 1173 2-hydroxy-2-methyl-1-phenyl-propan-1- Ciba oneGeigy Irgacure 184 1-hydroxycyclohexyl phenyl ketone Ciba Geigy Darocur4265 50% 2-hydroxy-2-methyl-1-phenyl-1one Ciba and 50% 2,4,6- Geigytrimehtylbenzoyldiphenylphosphine oxide Irgacure 9072-methyl-1-[-4-methylthio)phenyl]-2- Ciba morpholino propan-1-one GeigyIrgacure 1700 25% bis (2,6-dimethoxybenzoyl)-2,4-,4- Cibatrimethylpentyl phosphine oxide and 75% Geigy2-hydroxy-2-methyl-1-phenyl-propan-1- one Darocur BP Benzophenone CibaGeigy Irgacure 819 BAPO Phenyl bis(2,4,6-trimethylbenzoyl)- Cibaphosphine Oxide Geigy Lucrin MAPO Dipheny(2,4,6-trimethylbenzoyl)- Cibaphosphine oxide Geigy Irgacure 651 alpha, alpha-dimethoxy-alpha- Cibaphenylacetophenone Geigy

TABLE 2 List of Photosensitizers Trade Name Chemical Name Supplier ITXisopropyl thioxanthone Aceto CTX Chlorothioxanthone Aldrich Michlers4,4′-Bis(dimethylamino)benzophenone) Aldrich Ketone Thioxanthone AldrichBenzanthrone Aldrich triphenyl acetophenone Fluorenone

As illustrated in FIGS. 1 and 2, the pigmented high performance topcoat4 or wear layer 5 can be printed in register with a design in printlayer 6 which is disposed on the flooring substrate 2. This positionsthe pigmented high performance topcoat or wear layer for enhanced visualeffects. The topcoat 4 or wear layer 5 can be printed onto the substrate2 using various methods and apparatuses, such as screen printers,intaglio and flexo. The printing of the topcoat 4 or wear layer 5 is notlimited to any specific printing method so long as the method canachieve registration when registration is desired and achieve sufficientmaterial application to perform as a flooring surface.

In a further embodiment illustrated in FIG. 3, the printed substrate ofFIG. 1 can be chemically embossed and/or mechanically embossed.Additionally, the physical performance of the non-printed regions may beenhanced by the application of a radiation cured high performancetopcoat 4 as shown in FIG. 4. In this embodiment, the pigmented highperformance layers which are in register with the printed portions ofprint layer 6 are adjacent to and below the topcoat 4 and thereforebecome pigmented high performance wear layers 5. The high performancetopcoat 4 may include pigments for added visual effects.

Additionally, the pigmented high performance topcoat or wear layer canbe screen printed in register with the substrate after the substrate ischemically and/or mechanically embossed. Further, the up areas of FIG. 4can be mechanically embossed with a fine embossing pattern as shown inFIG. 5. Embossing changes the surface texture in the printed regions,which can be used to create additional visual effects.

In an additional embodiment, the colored high performance topcoat can beprinted in a pattern on the opposite side of a back printed film 10, asillustrated in FIGS. 6 and 7. The printed high performance topcoat 4 orwear layer 5 can be in register with the back printed pattern 6 forenhanced visual effects. If desired, a second topcoat can be appliedthat may or may not also comprise pigments for enhanced visual effects.The film 10 can itself be a composite film. It can also comprise a highperformance topcoat layer opposite the printed surface. Additionally,the film 10 does not have to be back printed. The resulting filmcomposite may be laminated to a flooring substrate and chemically and/ormechanically embossed to produce a flooring product.

A further embodiment includes “kiss-coating” the topcoat 4 onto theup-raised areas of an embossed substrate 2 or embossed film/substratecomposite as illustrated in FIG. 8. A clear high performance topcoat canalso be “kiss coated” on top of a pigmented radiation curable highperformance wear layer composition and subsequently cured to provide aunique visual effect while achieving high wear performance. Adifferential direct roll coater or other equipment that can easilytransfer the coating from the applicator of the coater to the up areascan be utilized. The resulting material can be over coated with anadditional clear or pigmented high performance topcoat if desired.

An additional method of applying the high performance topcoat 4 to anembossed film or flooring substrate includes “shade wiping” which isdescribed in U.S. Pat. Nos. 3,933,401 and 3,790,436 which areincorporated herein by reference. “Shade wiping” is a decoration termthat implies the uneven application of a colored material (usually ink)onto an embossed or textured surface where more of the colored materialstays in the deeper embossed regions relative to shallower embossedregions. The colored high performance topcoat composition 4 can be“shade wiped” into an embossed film or an embossed decorated flooringsubstrate 2 as shown in FIG. 9. This provides enhanced visual effectsnot achievable by decoration techniques below a clear wear surface. Thespecific method of shade wiping can be carried out by any process knownin the art such as by flexible blade or appropriately positioned airknife coater.

FIG. 10 shows a cross-sectional view of a decorative floor coveringillustrating a floor covering produced by chemically embossing asubstrate 2. The substrate 2 is printed with design pattern 6. Then awear layer 11 is applied covering the entire surface of the floorcovering and a screen printed radiation cured high performance wearlayer 5 is applied in register with the areas which become up areas whenthe composite is mechanically embossed. A high performance topcoat 4 isapplied over substantially the entire surface of the covering eitherbefore or after the mechanical embossing step.

There are no limitations to the nature of the pigments that can beutilized in this invention as long as the topcoat or wear layer achieveshigh performance properties after radiation curing. Additionally, thepigments should be color stable in the radiation curing process and thefinal resulting flooring product.

Incorporating nacreous pigments and especially interference colorpigments into the topcoat wear-surface composition aid in creating aninteraction with the light and dark portions of the printed patternsbelow the nacreous pigments. Nacreous pigments include those pigmentshaving iridescence, such as in mother-of-pearl or pigments having alustrous or attractive quality or effect. Examples of such pigments caninclude AFFLAIR Lustre pigments, AFFLAIR Ultra Interference pigments,and AFFLAIR Ultra Sparkle pigments obtained from EM Industries Inc., 5Skyline Drive, Hawthorn, N.Y. 10532; and MEARLIN, CELLINI, TIMICA,FLAMENCO, DUOCROME, CLOISONNE and GEMSTONE pigments available fromEngelhard Corp., Iselin, N.J. 00830-0770. Nacreous pigments may also beincluded in a second topcoat layer.

The following examples are intended to illustrate the invention and itis thought variations will occur to those skilled in the art.Accordingly, it is intended that the scope of the invention should belimited only by the appended claims.

EXAMPLES Example 1

A hydroxyl terminated polyester (PEI) was prepared as per example 1 ofU.S. Pat. No. 5,663,003 which is incorporated herein by reference. Thepolyester was prepared based upon the following composition: 1,6hexanediol 992.7 g Glycerine 133.5 g Phthalic Anhydride  1071 gDibutyltin Dilaurate  0.5 g

The reaction mixture was cooled, and the final product gave an Acid No.of 2.4 and a Hydroxyl No. of 179.

A coating composition was prepared as described in U.S. Pat. No.5,719,227, which is incorporated herein by reference. The followingcomposition was charged into a 2 L flask equipped with heating mantel,stirrer, and dry air purge at 0.25 SCFH: Tone M-100 Hydroxyacrylate fromUnion Carbide 126 g Monomer Mixture (27.5% by wt Sartomer SR499, 125 g27.5% by wt Sartomer SR502, 45% by wt of Sartomer SR351) PE1  35 g

The mixture was heated to 100° F. and 87 g of Desmodur N 3300isocyanurate trimer from Bayer Corp was added. The mixture was heated to185° F. and maintained for 5 hours. The mixture was cooled and to thecomposition was added with stirring Monomer mixture (27.5% by wt SartorSR499). 27.5% by wt Sartomer SR502, 15 g 45% by wt Sartomer SR351)Surfactant Dow Corning 193  1 g Benzophenone  4 g (this resulted intopcoat composition #1)

Example 2

Topcoat composition #1 was formulated with TiO₂ pigment obtained fromHuntsman (R-HD6X) and additional UV photoinitiators. The compositionswere preheated and coated onto a back printed rigid vinyl film at a 2mil thickness. The coated film was routed over a 12.75 inch heated drummaintained at about 150° F. At about 90° wrap, the film is exposed to UVirradiation either from a conventional medium pressure mercury vaporlamp or a doped (V bulb) lamp having a spectral output over the entireUV range 200-450 nm. The coated pigmented wear layer film is thenlaminated to a tile base. The coating had excellent adhesion and hadacceptable flooring wear performance as judged from a modified Taberabrasion test. Illustrated in Table 1 are the various formulations ofTiO₂ pigmented coatings. The amounts are in parts by weight unlessotherwise specified. TABLE 1 Table 1. Formulations of Pigmented CoatingsFor Example 1 A B C Composition 1 460 435 375 White Pigment 25 50 120Isodecyl acrylate(IDA) 110 Acrylic Acid 15 Lucrin TPO 7.5 4 Irgacure4265 16 Daracure 1173 7.5 7.5 Irgacure 907 ITX DC193 1.25 1.25 1.25Pigment conc 5 10 19 Coating Temperature (deg F.) 148 141 114 UVIntensity (mW/cm2) 914 837 (UVV) 837 (UVV) UV Bulb Type H V V Dosage(J/cm2) 2.4  2.5 (UVV)  2.5 (UVV) Thickness of Coating 2.1 2.2 1.9 CrossHatch Adhesion Pass Pass Pass Modified Taber Abraision Test Pass PassPass

Example 3

Top coat composition #1 was formulated with a pearlescent pigment(Golden Bronze 2.24 um, from Mearl Corp.), coated onto rigid vinyl film,and UV cured as per Example 2 using a medium pressure mercury vaporlamp. The cured topcoat has acceptable performance for use in flooringapplications. TABLE 2 Table 2. Formulations of Pigmented Coatings ForExample 3 A B C Composition 1 488.75 485 480 Pearl Pigment 1.25 5 10 Irg184 5 5 5 Benzophenone 5 5 5 Pigment Loading (% wt) 0.25 1 2 Intensity(mW/cm2, H bulb) 914 914 914 Dosage (J/cm2, UVA, H bulb) 2.4 2.4 2.4Thickness of Coating (mils) 2 2 2 Cross Hatch Adhesion Pass Pass PassModified Taber Abraision Test Pass Pass Pass

Example 4

The following additional topcoat compositions and pigment combinationswere radiation cured and evaluated. TABLE 3 % Loading TopCoat PigmentPigment Mfg. (wt) Thickness Cure #1 Afflair Pearl EM Industries   5% 1-4mils EB, UV U.S. Pat No. 5,663,003 Example 1 #2 Pennco Green Penn Color  1% 1-2 mils EB U.S. Pat No. 5,663,003 9G5inTMPTA Example 1 #3 InfiniteColor Sheshiedo 1.2% 1-3 mils UV U.S. Pat No. 5,891,582 Silver/GoldExample 1 #4 Infinite Color Sheshiedo 1%-3.1% 1-3 mils UV U.S. Pat No.5,891,582 Purple Example 1 #5 Infinite Color Sheshiedo 1.5% 2-3 mils UVU.S. Pat No. 5,891,582 Blue Example 1 GBG05SKE

The cured topcoats of table 3 were evaluated as done in Example 2 andshown to possess acceptable performance for use as high performancewear-surfaces in flooring products.

Example 5

A cushioned vinyl flooring substrate was prepared by applying andgelling a 5 mil plastisol base coat layer onto a felt backing layer (ca.25 mils). A foamable plastisol composition (10-11 mils) was then appliedand gelled on top of the plastisol basecoat layer. Thefelt/basecoat/foamable composite was then rotogravure printed with atleast one roto print ink containing a chemical embossing inhibitor. Theprinted composite was then coated with a clear vinyl plastisol wearlayer formulation and subsequently gelled. Onto this printed flooringsubstrate, the UV coating formulation #1 in Example 4, was applied inregister with the rotogravure printed design at a thickness of about 1mil. The composite was then heated, and the foamable layer expanded to20 mils through a standard fusion oven at 191° C. for 1.7 minutes, andthe UV coating cured by passing under UV lamps after it exits the fusionoven. The UV dosage was about 2.0 J/cm². The resultant product had apigmented high performance topcoat in register with the printed design.

Example 6

The unpigmented UV coating of formulation #1 in Example 4 was appliedoverall to the product of Example 5 and subsequently UV cured at adosage of 2.6 J/cm². The resultant product now comprises a two-componentUV cured topcoat/wear layer composite with one component pigmented andin register with the substrate printed design and one adjacentunpigmented component.

Example 7

A cushioned vinyl flooring substrate is prepared with a chemicallyembossed and mechanically embossed vinyl wear-surface. The pigmented UVcurable topcoat of Example 2 is applied by “kiss coating” the up regionsof the embossed vinyl flooring substrate surface so that the pigmentedtopcoat is only applied to up regions of the pattern. The “kiss coated”topcoat is then UV cured by passing it under UV lamps. The resultantproduct has a pigmented high performance topcoat located on the upregions imparting an enhanced visual effect.

Example 8

The product of Example 7 is post coated overall with a second UV curabletopcoat formulation #3 from Example 4 containing a nacreous,interference pigment composition. This second high performance topcoatinteracts with light and dark color regions of the pattern differentlyand imparts additional enhanced visual effects.

Example 9

A cushion vinyl flooring substrate with vinyl wear layer is chemicallyand mechanically embossed as described in U.S. Pat. No. 5,961,903 andincorporated herein by reference. An unpigmented high performancetopcoat of formulation 1 in Example 4 is air-knifed coated onto theembossed product at a thickness of about 1 mil such that the embossingtexture is substantially maintained and subsequently partially cured byexposure to UV radiation. The topcoat formulation of Example 2 is “shadewiped” into the embossing texture using a flexible blade coater andsubsequently the composite topcoat/wear layer is UV cured producing ahigh performance wear surface. The final visual has unique visualeffects due to varying degrees of opacity that cannot be duplicated byprinting techniques.

Example 10

A chemically embossed vinyl flooring substrate with a vinyl wear layeris prepared. Pigmented UV coating composition of Example 3 is screenprinted in register with the substrate design pattern and partiallycured by WV. The substrate is then mechanically embossed as in U.S. Pat.No. 5,961,903 and subsequently air-knife coated with a secondunpigmented UV topcoat (formulation 1 of Example 4) and the UV topcoatcomposite is completely cured by passing under UV lights resulting in ahigh performance topcoat/wear layer surface.

Example 11

The topcoat formulation from Example 3 is intaglio printed onto the topsurface of a back printed, rigid vinyl film in register with the backprinted design. The topcoat formulation is partially cured by exposureto 125 KeV EB radiation. The resultant discontinuous top coated film isthen overcoated with an unpigmented topcoat formulation and the entiretopcoat composite completely cured by exposure to 4 Mrads of 125 KeV EBradiation. The resultant topcoat/wear layer composite film is laminatedonto a flooring tile base and subsequently mechanically embossed inregister with the back printed design.

Example 12

A rigid vinyl film is rotogravure back printed, wherein at least one ofthe rotogravure inks contains a chemical embossing inhibitor. This backprinted film is subsequently topcoat printed in register as per Example11 to produce a partially EB radiation cured registeredtopcoat/back-printed film. This registered topcoat/back-printed film issubsequently laminated onto the felt/foamable composite of Example 5 andprocessed similar to Example 5 to produce a chemically embossedcushioned vinyl structure with the film/topcoat surface. This structureis subsequently air-knife coated with an unpigmented UV curablecomposition of Example 1 and subsequently cured by exposure to UVirradiation. The final flooring product has a radiation cured highperformance wear layer/topcoat surface.

While specific embodiments have been set forth as illustrated anddescribed above, it is recognized that variations may be made withrespect to disclosed embodiments. Therefore, while the invention hasbeen disclosed in various forms only, it will be obvious to thoseskilled in the art that many additions, deletions and modifications canbe made without departing from the spirit and scope of this invention,and no undue limits should be imposed except as set forth in thefollowing claims.

1. A decorative floor covering comprising a substrate; and a radiationcured pigmented wear layer disposed on the substrate, the floor coveringhaving an exposed wear surface with a stain resistance of less thanabout 150 Delta E units, wherein the wear layer consists essentially ofat least one thermoset polymer and an ingredient selected from the groupconsisting of pigments, photoinitators, photosensitizers, surfactants,reactive monomers and combinations thereof, wherein the thermosetpolymer is selected from the group consisting of ultraviolet lightcurable polymers, electron beam curable polymers and combinationsthereof.
 2. The decorative floor covering of claim 1, wherein theradiation cured pigmented wear layer has a gloss retention of at leastabout 80%.
 3. The decorative floor covering of claim 1, wherein thethermoset polymer is selected from the group consisting of acrylatedpolyesters, acrylated polyurethanes, vinyl ether polymers, maleic acidpolyesters, epoxy polymers, epoxy acrylate polymers and mixturesthereof. 4 (Canceled).
 5. The decorative floor covering of claim 1,wherein a printed pattern is interposed between the substrate and thewear layer.
 6. The decorative floor covering of claim 5, wherein thepigmented wear layer is in register with the printed pattern.
 7. Thedecorative floor covering of claim 1, wherein the substrate has atextured surface selected from the group consisting of a mechanicallyembossed texture, chemically embossed texture, and a chemically andmechanically embossed texture.
 8. The decorative floor covering of claim7, wherein the pigmented wear layer is in register with the embossedtexture.
 9. The decorative floor covering of claim 7, wherein theembossed texture has raised surfaces and indentations, and the pigmentedwear layer is disposed mainly on the raised surfaces.
 10. The decorativefloor covering of claim 7, wherein the embossed texture has raisedsurfaces and indentations, and the pigmented wear layer is disposedmainly in the indentations.
 11. The decorative floor covering of claim1, wherein the pigment is a nacreous pigment.
 12. The decorative floorcovering of claim 1, further comprising a radiation cured topcoatdisposed on and adjacent to the radiation cured pigmented wear layer,wherein the topcoat consists essentially of at least one thermosetpolymer and an ingredient selected from the group consisting ofpigments, photoinitators, photosensitizers, surfactants, reactivemonomers and combinations thereof, wherein the thermoset polymer isselected from the group consisting of ultraviolet light curablepolymers, electron beam curable polymers, and combinations thereof. 13.The decorative floor covering of claim 12, wherein the radiation curedtopcoat has a gloss retention of at least about 80%.
 14. The decorativefloor covering of claim 12, wherein the thermoset polymer of the topcoatand the wear layer is selected from the group consisting of acrylatedpolyesters, acrylated polyurethanes, vinyl ether polymers, maleic acidpolyesters, epoxy polymers, epoxy acrylate polymers and mixturesthereof. 15 (Canceled).
 16. The decorative floor covering of claim 12,wherein a printed pattern is interposed between the substrate and thetopcoat.
 17. The decorative floor covering of claim 16, wherein thetopcoat or pigmented wear layer is in register with the printed pattern.18. The decorative floor covering of claim 12, wherein the substrate hasa textured surface selected from the group consisting of mechanicallyembossed texture, chemically embossed texture, and chemically andmechanically embossed texture.
 19. The decorative floor covering ofclaim 18, wherein the topcoat or pigmented wear layer is in registerwith the embossed texture.
 20. The decorative floor covering of claim18, wherein the embossed texture has raised surfaces and indentations,and the topcoat or pigmented wear layer is disposed mainly on the raisedsurfaces.
 21. The decorative floor covering of claim 18, wherein theembossed texture has raised surfaces and indentations, and the topcoator pigmented wear layer is disposed mainly in the indentations.
 22. Thedecorative floor covering of claim 56, wherein pigment of the topcoat orpigmented wear layer is a nacreous pigment.
 23. A decorative floorcovering component comprising a rigid vinyl film; and a radiation curedpigmented wear layer disposed on the rigid vinyl film, the floorcovering component having an exposed wear surface with a stainresistance of less than about 150 Delta E units, wherein the wear layerconsists essentially of at least one thermoset polymer and an ingredientselected from the group consisting of pigments, photoinitators,photosensitizers, surfactants, reactive monomers and combinationsthereof, wherein the thermoset polymer is selected from the groupconsisting of ultraviolet light curable resins, electron beam curableresins, and combinations thereof.
 24. The decorative floor coveringcomponent of claim 23, wherein the rigid vinyl film further comprises aprinted pattern disposed on the film opposite the pigmented wear layer.25. The decorative floor covering component of claim 24, wherein theradiation cured pigmented wear layer is disposed in register with theprinted pattern.
 26. The decorative floor covering of claim 12, whereinthe substrate comprises a laminated film.
 27. The decorative floorcovering of claim 26, wherein the substrate further comprises a printedpattern disposed on the film opposite the wear layer.
 28. The decorativefloor covering of claim 27, wherein the radiation cured pigmented wearlayer is disposed in register with the printed pattern. 29-55.(Canceled).
 56. The decorative floor covering of claim 12, wherein theradiation cured topcoat is pigmented.
 57. The decorative floor coveringof claim 56, wherein the substrate has a textured surface selected fromthe group consisting of mechanically embossed texture, chemicallyembossed texture, and chemically and mechanically embossed texture. 58.The decorative floor covering of claim 57, wherein the embossed texturehas raised surfaces and indentations, and the pigmented topcoat isdisposed mainly on the raised surfaces.
 59. The decorative floorcovering of claim 57, wherein the embossed texture has raised surfacesand indentations, and the pigmented topcoat is disposed mainly in theindentations.